Crack resistant hardfacing alloys

ABSTRACT

Embodiments of an alloy that can be resistant to cracking. In some embodiments, the alloy can be advantageous for use as a hardfacing alloys, in both a diluted and undiluted state. Certain microstructural, thermodynamic, and performance criteria can be met by embodiments of the alloys that may make them advantageous for hardfacing.

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

Any and all applications for which a foreign or domestic priority claimis identified in the Application Data Sheet as filed with the presentapplication are hereby incorporated by reference under 37 CFR 1.57.

BACKGROUND

1. Field

The disclosure generally relates to hardfacing weld overlays used toprotect components subject to abrasion

2. Description of the Related Art

Hardfacing and/or weld overlays are commonly used in a variety ofapplications to protect components from excessive material loss inabrasive environments. In certain applications it can be desirable forthe hardfacing overlay to remain crack free after the welding process iscomplete. This is not typical of hardfacing alloys as many stressrelieve crack during or immediately after welding due to the inherentlow toughness of the alloy. Hardfacing alloys are typically very hard,in excess of 50 HRC, and it is well known by those skilled in the art ofmetallurgy that hardness is generally inversely related to toughness. Incertain applications, it is further desirable to weld over the originalworn down layer of the hardfacing, and to do so without generatingcracks in the original or secondary weld overlay. In such applicationsit is often desirable to continuously weld over worn layers again andagain as wear occurs on the existing hardfacing to continuously repairand re-build the hardfacing layer. In the process of re-buildinghardfacing layers in this manner, it is commonplace to weld a hardfacingalloy of one type over a hardfacing layer of a second different type. Itis generally desirable to do be able to do so without introducing anyloss in performance.

Two types of cracks are known to commonly occur in hardfacing. Thefirst, stress cracks, are very common and easy to detect. These cracksoccur due to the weld bead contracting as it cools, resulting in thermalstresses being built up in the weld to a level which creates cracks inthe weld. The second, hot tears, are less common, and less detectable asthey do not create loud crack ‘ping’s during the welding process. Hottears occur when the alloy solidifies over a larger temperature, and theedges of the bead begin to solidify and contract while the center of thebead has not yet fully solidified. The contraction of the outer beadpulls the liquid phase at the center of the bead apart. This mechanismis also known to those skilled in the art of metallurgy.

An example of a specific application where the problems of stresscracking and hot tearing commonly occur is hardbanding. Hardbanding isthe process of protecting the drill pipe, generally in the form of twoor more weld beads deposited onto the tool joint. It is common and alsodesirable to deposit additional overlays onto worn hardbands to rebuildthe wear resistant surface. As drill pipe is commonly rented out tovarious drilling sites, and it is also common to apply one type ofhardbanding alloy over a second hardbanding alloy of a different type.The current available selection of hardbanding alloys is relativelydiverse; many form wear resistance through the carbide formation, andmany others through boride formation. Welding a carbide forming alloyover a boride forming alloy creates conditions where the re-buildinglayer is very likely to either stress crack or hot tear.

One example of an alloy which is highly resistant to hot tearing, but issubject to stress cracking is presented in U.S. Pat. No. 8,647,449: Fe:bal, Cr: 5, Nb: 4, V: 0.5, C: 0.8, B: 0.9, Mo: 3.5, Ti: 0.2, Si: 0.5,Mn: 1, hereby incorporated by reference in its entirety. This alloy canbe welded as a single layer, but is increasingly likely to stress crackwith subsequent re-building layers. The general class of materials whichexhibit this type of behavior can form either primary carbides orborides, and also form eutectic carbides or borides in excess of 15volume %. This classification is based upon extensive research conductedwithin this study. An example of such an alloy is shown in FIG. 1(left), where the both carbides [101] and borides [102] exist in aferritic matrix [103], but the eutectic borides are present at about 20volume %.

One example of an alloy which is highly resistant to stress cracking,but subject to hot tearing is that presented in WO 2014/127062 (whichclaims priority to U.S. 61/889,548, filed Nov. 4, 2013): Fe: bal, C: 1,Cr: 5, Mn: 1.1, Mo: 0.75, Ni: 0.1, Si: 0.77, Ti: 3; WO 2014/127062 andU.S. 61/889,548 are hereby incorporated by reference in its entirety.This alloy can be re-built over worn layers of a similar typeindefinitely without stress cracking or hot tearing. However, when thisalloy is welded over a worn hardbanding layer containing B, it will hottear. The general class of materials which exhibit this type of behaviorform either primary carbides or borides (carbides or borides whichprecipitate from the liquid prior to the austenite matrix phase), but donot form both carbide and boride. An example of an alloy susceptible tohot tearing is shown in FIG. 1 (right), where primary carbides [104] areembedded in a martensitic matrix [105]; the lack of any eutecticcarbides or borides, and the lack of borides in the microstructurecreate increased likelihood for hot tearing.

The current state of the art for hardfacing materials possess alloyswhich fall into either of these two general categories. Thus, there is aneed for a class of hardfacing materials which are resistant to both ofthese forms of failure: stress cracking and hot tearing.

SUMMARY

In some embodiments, computational metallurgy can be used to explorealloy compositional ranges where several thermodynamic criteria aremet: 1) the total grain boundary carbide/boride fraction can be lessthan 15 volume % (or less than about 15 volume %) in the undilutedstate, 2) the grain boundary carbide/boride formation temperature can beno less than 80K (or no less than about 80K) below the liquidustemperature of the matrix phase in the undiluted and diluted state, 3)the minimum C level in the matrix can be greater than 0.6 weight % (orgreater than about 0.6 weight %), 4) the alloy can contain both C and B.When this set of thermodynamic criteria are met, the resultant alloy canbe highly resistant to stress cracking and hot tearing. Themicrostructure can possess a primarily martensitic matrix with bothcarbide and boride precipitates with the eutectic carbides and/orborides not being present in excess of 15 volume %. The utility of sucha material can be a hardfacing alloy which is highly wear resistant, andcan be deposited crack free as a single layer and as a rebuilding layerover itself, over carbon containing hardfacing materials, and over boroncontaining hardfacing materials without stress cracking or hot tearing.

Disclosed herein are embodiments of an article of manufacture which canbe used as a feedstock for hardfacing weld overlay whereby the articlecomprises a macro-hardness of 50 HRC or greater and a high resistance tostress cracking and hot tearing when welded as a single layer or over aworn existing hardfacing layer, wherein a worn hardfacing layer ischaracterized by any alloy which contains a total sum of carbon and/orboron up to 3 weight %.

In some embodiments, the alloy can have high abrasion resistance ascharacterized by an ASTM G65A mass loss of less than 0.5 grams. In someembodiments, the resultant hardfacing deposit can contain both carbideand boride precipitates.

In some embodiments, the resultant hardfacing deposit can containgreater than 0 volume % grain boundary carbides and/or borides but lessthan 15 volume % grain boundary precipitates. In some embodiments, theresultant hardfacing deposit can contain greater than 0 volume % grainboundary carbides and/or borides but less than 15 volume % grainboundary precipitates when present a fully undiluted and a fully dilutedstate.

In some embodiments, the feedstock alloy or layer can comprise, in wt.%, Fe: bal, B: 0-6-0.9, C: 0.75-1.25, Cr: 14.25-26, and Nb+Ti+V:3.5-4.5. In some embodiments, the feedstock alloy or layer can furthercomprise, in wt. %, Mn: about 1.1, Mo: about 1, Si: about 0.5.

Also disclosed herein are embodiments of a work piece having at least aportion of its surface covered by a layer, wherein the layer comprises amacro-hardness of 50 HRC or greater, the layer containing both carbidesand borides, and a volume fraction of less than 10% eutectic carbidesand/or borides.

In some embodiments, the volume fraction of eutectic carbide and/orborides can be greater than 0%. In some embodiments, the microstructurecan contain primary Nb and/or Ti rich carbides. In some embodiments, themicrostructure can contain eutectic Cr rich borides. In someembodiments, the alloy can have high abrasion resistance ascharacterized by an ASTM G65A mass loss of less than 0.5 grams.

In some embodiments, the feedstock alloy or layer can comprise, in wt.%, Fe: bal, B: 0-6-0.9, C: 0.75-1.25, Cr: 14.25-26, and Nb+Ti: 3.5-4.5.In some embodiments, the feedstock alloy or layer can further comprise,in wt. %, Mn: about 1.1, Mo: about 1, Si: about 0.5.

Also disclosed herein are embodiments of a method of forming a coatedworkpiece comprising depositing an alloy layer on at least a portion ofthe workpiece wherein the alloy comprises the following thermodynamicfeatures: less than 10 mole fraction carbides and/or borides at 1300K,at least one carbide and one boride phase at 1300K, and eutecticcarbides and/or borides at no less than 80K below the liquidustemperature of the ferritic or austenitic iron matrix phase.

In some embodiments, the minimum carbon content in the liquid phase canbe 0.5 wt. %. In some embodiments, the alloy can contain eutecticcarbides and/or borides at no less than 80K below the liquidustemperature of the ferritic or austenitic iron matrix phase in the fullydiluted state. In some embodiments, the alloy can have high abrasionresistance as characterized by an ASTM G65A mass loss of less than 0.5grams.

In some embodiments, the feedstock alloy or layer can comprise, in wt.%, Fe: bal, B: 0-6-0.9, C: 0.75-1.25, Cr: 14.25-26, and Nb+Ti: 3.5-4.5.In some embodiments, the feedstock alloy or layer can further comprise,in wt. %, Mn: about 1.1, Mo: about 1, Si: about 0.

Disclosed herein are embodiments of a metal alloy composition,comprising an Fe-based alloy comprising alloying elements of boron,carbon, chromium, and niobium, titanium and/or vanadium, wherein themaximum eutectic carbide/boride phase fraction of the alloy is about 15mole %, wherein the maximum grain boundary formation temperature gap ofthe alloy is about 80K, wherein the minimum carbon level in the liquidis about 0.5 wt. %, and wherein the alloy comprises both carbides andborides, and the carbides are thermodynamically stable at a temperatureequal to or greater than about 80K below the liquid temperature of theaustenite or ferrite matrix phase.

In some embodiments, the alloy can be primarily martensitic. In someembodiments, carbide and boride precipitates may not exceed about 15volume %. In some embodiments, the alloy can be provided as a hardfacingweld overlay. In some embodiments, the alloy can be provided as a singlelayer onto a component. In some embodiments, the alloy can be providedas multiple layers over a worn hardfacing layer.

Also disclosed herein are embodiments of an article of manufacture foruse as a feedstock for hardfacing weld overlay, wherein the articlecomprises an alloy having a macro-hardness of 50 HRC or greater and ahigh resistance to stress cracking and hot tearing when welded as asingle layer or over a worn existing hardfacing layer, wherein the wornexisting hardfacing layer is characterized by any alloy which contains atotal sum of carbon and or boron up to 3 weight %.

In some embodiments, the alloy can have high abrasion resistance ascharacterized by an ASTM G65A mass loss of less than 0.5 grams. In someembodiments, a resultant hardfacing deposit of the alloy over the wornexisting hardfacing layer can contain both carbide and borideprecipitates. In some embodiments, a resultant hardfacing deposit of thealloy over the worn existing hardfacing layer can contain greater than 0volume % grain boundary carbides and/or borides but less than 15 volume% grain boundary precipitates. In some embodiments, a resultanthardfacing deposit of the alloy over the worn existing hardfacing layercan contain greater than 0 volume % grain boundary carbides and/orborides but less than 15 volume % grain boundary precipitates whenpresent a fully undiluted and a fully diluted state.

In some embodiments, the alloy can comprise Fe and, in wt. %:

B: 0.6-0.9;

C: 0.75-1.25;

Cr: 14.25-26; and

Nb+Ti+V: 3.5-4.5.

In some embodiments, the alloy can further comprise, in wt. %:

Mn: about 1.1;

Mo: about 1; and

Si: about 0.5.

Also disclosed herein are embodiments of a work piece having at least aportion of its surface covered by a layer, wherein the layer comprisesan alloy having a macro-hardness of 50 HRC or greater, the alloycontaining both carbides and borides, and wherein the alloy comprises avolume fraction of less than 10% eutectic carbides and/or borides.

In some embodiments, the volume fraction of eutectic carbide and/orborides can be greater than 0%. In some embodiments, a microstructure ofthe alloy can comprise primary Nb and/or Ti rich carbides. In someembodiments, a microstructure of the alloy can comprise eutectic Cr richborides. In some embodiments, the alloy can have high abrasionresistance as characterized by an ASTM G65A mass loss of less than 0.5grams.

In some embodiments, the alloy can comprise Fe and, in wt. %:

B: 0.6-0.9;

C: 0.75-1.25;

Cr: 14.25-26; and

Nb+Ti+V: 3.5-4.5.

In some embodiments, the alloy can further comprise, in wt. %:

Mn: about 1.1;

Mo: about 1; and

Si: about 0.5.

Also disclosed herein are embodiments of a method of forming a coatedworkpiece comprising depositing an alloy layer on at least a portion ofthe workpiece wherein the alloy layer comprises the followingthermodynamic features less than 10 mole fraction carbides and/orborides at 1300K, at least one carbide and one boride phase at 1300K,and eutectic carbides and/or borides at no less than 80K below theliquidus temperature of the ferritic or austenitic iron matrix phase.

In some embodiments, a minimum carbon content in a liquid phase of thealloy layer can be 0.5 wt. %. In some embodiments, the alloy layer cancomprise eutectic carbides and/or borides at no less than 80K below theliquidus temperature of a ferritic or austenitic iron matrix phase ofthe alloy layer in a fully diluted state. In some embodiments, the alloylayer can have high abrasion resistance as characterized by a ASTM G65Amass loss of less than 0.5 grams.

In some embodiments, the alloy layer can comprise Fe and, in wt. %:

B: about 0.1 to about 1.1;

C: about 0.6 to about 2;

Cr: about 0.5 to about 22;

Mn: about 0 to about 1.15;

Mo: about 0 to about 1;

Nb: about 0 to about 8;

Si: about 0 to about 0.65;

Ti: about 0 to about 8;

V: about 0 to about 10;

W: about 0 to about 4; and

Zr: about 0 to about 8.

In some embodiments, the alloy layer can comprise Fe and, in wt. %:

B: 0.6-0.9;

C: 0.75-1.25;

Cr: 14.25-26; and

Nb+Ti+V: 3.5-4.5.

In some embodiments, the alloy layer can further comprise, in wt. %:

Mn: about 1.1;

Mo: about 1; and

Si: about 0.5.

Other methods are also contemplated in this disclosure as well, such ashardfacing or hardbanding procedures. For example, a single, ormultiple, layers of an alloy can be applied over a substrate.

Also disclosed herein are embodiments of an alloy for hardfacing over asubstrate, the alloy comprising a matrix comprising at least about 10%by volume martensite, and a grain boundary carbide and/or boride volumefraction of below about 15%, where both carbides and borides arepresent.

In some embodiments, the alloy can have a composition of Fe and, inweight percent:

about 0.52 to about 0.9 B;

about 0.68 to about 1.25 C;

about 8.36 to about 16.1 Cr; and

about 3 to about 4.5 Nb.

Also disclosed herein are embodiments of an alloy for hardfacing over asubstrate, the alloy comprising a minimum hardness of about 50 HRC, aminimum wear resistance of 0.5 g lost according to ASTM G65 Procedure A,a lack of hot tearing when welded as a hardfacing alloy on a substratecontaining carbon and/or boron, and a lack of stress cracking whenwelded on the substrate containing carbon and/or boron.

In some embodiments, the alloy can further comprise a matrix comprisingat least about 10% by volume martensite, and a grain boundary carbideand/or boride volume fraction of below about 15%, where both carbidesand borides are present.

In some embodiments, the alloy can have a composition of Fe and, inweight percent:

about 0.52 to about 0.9 B;

about 0.68 to about 1.25 C;

about 8.36 to about 16.1 Cr; and

about 3 to about 4.5 Nb.

In some embodiments, the maximum eutectic carbide/boride phase fractionof the alloy can be about 15 mole %, wherein the maximum grain boundaryformation temperature gap of the alloy can be about 80K, wherein theminimum carbon level in the liquid can be about 0.5 wt. %, and whereinthe alloy can comprise both carbides and borides, and the carbides canbe thermodynamically stable at a temperature equal to or greater thanabout 80K below the liquid temperature of the austenite or ferritematrix phase.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example of microstructures of hardfacing alloyssusceptible to stress cracking (left) and hot tearing (right).

FIG. 2 illustrates a solidification diagram for an embodiment of adisclosed alloy (Alloy #86) in fully undiluted composition.

FIG. 3 illustrates a solidification diagram for an embodiment of adisclosed alloy (Alloy #86) in fully diluted composition.

FIG. 4 illustrates an SEM micrograph of an embodiment of a disclosedalloy (Alloy P20X86) at 1,000× (left) and 3,000× (right) magnification.

DETAILED DESCRIPTION

Disclosed herein are embodiments of crack resistant alloys, and methodsof manufacturing the alloys, which can be used in particular forhardfacing applications. In some embodiments, computational metallurgycan be used to explore alloy compositional ranges which can achievecertain parameters, discussed in detail below.

Metal Alloy Composition

It has been determined through thermodynamic analysis andexperimentation that alloying elements (to be added to an Fe-basedcomposition) which can be used for ensuring the microstructural andperformance criteria specified in certain embodiments of this disclosureare B, C, Cr, Nb, and Ti. In addition to these alloying elements,secondary alloying elements can be added to further enhance theperformance, such as Al, Si, V, Mn, Ni, Cu, Zr, and W among others. Inaddition, typical impurities such as S, P, and others, can be present inthe manufactured form of these alloys.

Embodiments of this alloy can describe a unique class of alloys whichpossess the disclosed microstructural features and exhibit the disclosedperformance criteria when welded as a single layer onto a component(diluted), when welded multiple times over worn hardfacing layers(undiluted, typically requiring 4 or more re-building layers), as wellas any intermediate layer chemistries produced during reapplications.Dilution can occur in a weld as some of the base material (e.g., thesubstrate that the weld is being applied to), can infiltrate the welditself during the welding operation, thus diluting the weld compositionwith the composition of the substrate. Thus, for every layer that isadded on, dilution can be reduced as the weld is no longer in directcontact with the base material, but instead is in contact with otherdiluted or undiluted welds. Thus, in some examples the first layer couldbe a diluted layer, while layers 2-3 could be intermediate layers, and afourth layer could be an undiluted layer, though which layer is whichcan depend on the chemistry of the welds and the substrate.

In some embodiments, the diluted chemistry can contain about 5-30% (orabout 5 to about 30%) by weight the chemistry of the base material mixedwith the remainder chemistry of the feedstock. During subsequentre-applications of the hardfacing alloy over worn layers, the chemistryof the re-applied layer can be increasingly enriched until it approachesthe chemistry of the weld feedstock. The compositions described hereincan refer to the feedstock composition, the diluted composition of asingle layer weld, the undiluted composition of a weld layer producedfrom multiple reapplications as well as any intermediate weld layercompositions ranging from the fully diluted state to the fully undilutedstate.

In some embodiments, the alloy can be described by a composition inweight percent comprising the following elemental ranges which have beenproduced and evaluated experimentally and which met the disclosedmicrostructural criteria:

Fe: Balance

B: 0.6 to 0.9 (or about 0.6 to about 0.9)

C: 0.75 to 1.25 (or about 0.75 to about 1.25)

Cr: 14.25 (or about 14.25)

Nb: 3.5 to 4.5 (or about 3.5 to about 4.5)

Further elements which can be added, primarily for manufacturability andprocessing control, are:

Mn: 1.1 (or about 1.1)

Mo: 1 (or about 1)

Si: 0.5 (or about 0.5)

Ti: 0.5 (or about 0.5)

V 0.5 (or about 0.5)

In some embodiments, the alloy can be described by a compositions inweight percent comprising the following elemental ranges including thoseevaluated experimentally and using thermodynamic modeling tools:

Fe: Balance

B: 0.6 to 0.9 (or about 0.6 to about 0.9)

C: 0.75 to 1.25 (or about 0.75 to about 1.25)

Cr: 14.25 to 26 (or about 14.25 to about 26)

Nb: 3.5 to 4.5 (or about 3.5 to about 4.5)

Further elements which can be added, primarily for manufacturability andprocessing control, are:

Mn: 1.1 (or about 1.1)

Mo: 1 (or about 1)

Si: 0.5 (or about 0.5)

Ti: 0.5 (or about 0.5)

V 0.5 (or about 0.5)

In some embodiments, the Nb content in the alloy can be exchanged fullyor partially with Ti and/or V as both form primary carbides in alloys ofthis type. In some embodiments, the Nb+Ti+V concentration in weight % ofthe disclosed alloys can be between 3.5 and 4.5 (or between about 3.5and about 4.5). In some embodiments, the Nb+Ti concentration in weight %can be between 3.5 and 4.5 (or between about 3.5 and about 4.5).

In some embodiments, the alloy can be described by specific compositionsin weight percent comprising the following elements, which have beenproduced and evaluated experimentally and which met the disclosedmicrostructural and performance criteria:

Fe: Balance

B: 0.75 (or about 0.75)

C: 0.75 to 0.95 (or about 0.75 to about 0.95)

Cr: 14.25 (or about 14.25)

Nb: 3.5 (or about 3.5)

Further elements which can be added, primarily for manufacturability andprocessing control, are:

Mn: 1.1 (or about 1.1)

Mo: 1 (or about 1)

Si: 0.5 (or about 0.5)

Ti: 0.5 (or about 0.5)

V 0.5 (or about 0.5)

In some embodiments, the alloy can be described by specific compositionsin weight percent comprising the following elemental ranges as definedthrough glow discharge spectrometer readings, which have been producedand evaluated experimentally and which met the disclosed microstructuraland performance criteria:

Fe: Balance

B: 0.52 to 0.75 (or about 0.52 to about 0.75)

C: 0.68 to 1.1 (or about 0.68 to about 1.1)

Cr: 8.36 to 16.1 (or about 8.36 to about 16.1)

Nb: 3 to 4 (or about 3 to about 4)

Further elements which can be added primarily for manufacturability andprocessing control are:

Mn: 1.05 to 1.1, Mo: 0.85 to 1.02, Si: 0.52 to 0.59, Ti: 0.39 to 0.85,and V: 0.39 to 0.46; or

Mn: about 1.05 to about 1.1, Mo: about 0.85 to about 1.02, Si: about0.52 to about 0.59, Ti: about 0.39 to about 0.85, and V: about 0.38 toabout 0.46

In some embodiments, the alloy can be described by specific compositionsin weight percent comprising the following elemental ranges as definedthrough glow discharge spectrometer readings, which have been producedand evaluated experimentally and which met the disclosed microstructuraland performance criteria:

Fe: Balance

B: 0.52 to 0.9 (or about 0.52 to about 0.9)

C: 0.68 to 1.25 (or about 0.68 to about 1.25)

Cr: 8.36 to 26 (or about 8.36 to about 16.1)

Nb: 3 to 4.5 (or about 3 to about 4.5)

Further elements which can be added primarily for manufacturability andprocessing control are:

Mn: 1.05 to 1.1, Mo: 0.85 to 1.02, Si: 0.52 to 0.59, Ti: 0.39 to 0.85,and V: 0.39 to 0.46; or

Mn: about 1.05 to about 1.1, Mo: about 0.85 to about 1.02, Si: about0.52 to about 0.59, Ti: about 0.39 to about 0.85, and V: about 0.38 toabout 0.46

In some embodiments, the alloy can be described by compositional rangeswhich meet the thermodynamic criteria described in this disclosure.These alloys can comprise the following:

Fe: Balance

B: 0.1 to 1.1 (or about 0.1 to about 1.1)

C: 0.6 to 2 (or about 0.6 to about 2)

Cr: 0.5 to 22 (or about 0.5 to about 22)

Mn: 0 to 1.15 (or about 0 to about 1.15)

Mo: 0 to 1 (or about 0 to about 1)

Nb: 0 to 8 (or about 0 to about 8)

Si: 0 to 0.65 (or about 0 to about 0.65)

Ti: 0 to 8 (or about 0 to about 8)

V: 0 to 10 (or about 0 to about 10)

W: 0 to 4 (or about 0 to about 4)

Zr: 0 to 8 (or about 0 to about 8)

Further elements which can be added primarily for manufacturability andprocessing control are:

Mn: 1.05 to 1.1, Mo: 0.85 to 1.02, Si: 0.52 to 0.59, Ti: 0.39 to 0.85,and V: 0.39 to 0.46; or

Mn: about 1.05 to about 1.1, Mo: about 0.85 to about 1.02, Si: about0.52 to about 0.59, Ti: about 0.39 to about 0.85, and V: about 0.38 toabout 0.46

In some embodiments, the alloy can be described by the specificexemplary compositions which met either the performance and/ormicrostructural criteria, comprising a mixture of one or more of thefollowing (in all cases Fe forming the balance):

-   -   B: 0.6, C: 1, Cr: 14.25, Mn: 1.1, Mo: 1, Nb: 4.5, Si: 0.5, Ti:        0.5, and V: 0.5 (or B: about 0.6, C: about 1, Cr: about 14.25,        Mn: about 1.1, Mo: about 1, Nb: about 4.5, Si: about 0.5, Ti:        about 0.5, and V: about 0.5)    -   B: 0.9, C: 1.1, Cr: 14.25, Mn: 1.1, Mo: 1, Nb: 3.5, Si: 0.5, Ti:        0.5, and V: 0.5 (or B: about 0.9, C: about 1.1, Cr: about 14.25,        Mn: about 1.1, Mo: about 1, Nb: about 3.5, Si: about 0.5, Ti:        about 0.5, and V: about 0.5)    -   B: 0.75, C: 1.05, Cr: 14.25, Mn: 1.1, Mo: 1, Nb: 3.5, Si: 0.5,        Ti: 0.5, and V: 0.5 (or B: about 0.75, C: about 1.05, Cr: about        14.25, Mn: about 1.1, Mo: about 1, Nb: about 3.5, Si: about 0.5,        Ti: about 0.5, and V: about 0.5)    -   B: 0.6, C: 1, Cr: 14.25, Mn: 1.1, Mo: 1, Nb: 4.5, Si: 0.5, Ti:        0.5, and V: 0.5 (or B: about 0.6, C: about 1, Cr: about 14.25,        Mn: about 1.1, Mo: about 1, Nb: about 4.5, Si: about 0.5, Ti:        about 0.5, and V: about 0.5)    -   B: 0.75, C: 1.05, Cr: 14.25, Mn: 1.1, Mo: 1, Nb: 3.5, Si: 0.5,        Ti: 0.5, and V: 0.5 (or B: about 0.75, C: about 1.05, Cr: about        14.25, Mn: about 1.1, Mo: about 1, Nb: about 3.5, Si: about 0.5,        Ti: about 0.5, and V: about 0.5)    -   B: 0.75, C: 1.25, Cr: 14.25, Mn: 1.1, Mo: 1, Nb: 3.5, Si: 0.5,        Ti: 0.5, and V: 0.5 (or B: about 0.75, C: about 1.25, Cr: about        14.25, Mn: about 1.1, Mo: about 1, Nb: about 3.5, Si: about 0.5,        Ti: about 0.5, and V: about 0.5)    -   B: 0.75, C: 0.95, Cr: 14.25, Mn: 1.1, Mo: 1, Nb: 3.5, Si: 0.5,        Ti: 0.5, and V: 0.5 (or B: about 0.75, C: about 0.95, Cr: about        14.25, Mn: about 1.1, Mo: about 1, Nb: about 3.5, Si: about 0.5,        Ti: about 0.5, and V: about 0.)    -   B: 0.75, C: 0.85, Cr: 14.25, Mn: 1.1, Mo: 1, Nb: 3.5, Si: 0.5,        Ti: 0.5, and V: 0.5 (B: about 0.75, C: about 0.85, Cr: about        14.25, Mn: about 1.1, Mo: about 1, Nb: about 3.5, Si: about 0.5,        Ti: about 0.5, and V: about 0.5)    -   B: 0.75, C: 0.75, Cr: 14.25, Mn: 1.1, Mo: 1, Nb: 3.5, Si: 0.5,        Ti: 0.5, and V: 0.5 (or B: about 0.75, C: about 0.75, Cr: about        14.25, Mn: about 1.1, Mo: about 1, Nb: about 3.5, Si: about 0.5,        Ti: about 0.5, and V: about 0.5)

The Fe content identified in all of the compositions described in theabove paragraphs may be the balance of the composition as indicatedabove, or alternatively, the balance of the composition may comprise Feand other elements. In some embodiments, the balance may consistessentially of Fe and may include incidental impurities.

Table 1 below illustrates a listing of some alloys compositions producedusing embodiments of the above-described compositions.

TABLE 1 Alloys Compositions Produced into Experimental Ingots andWelding Wires ALLOY B C Cr Mn Mo Nb Si Ti V 1 1.45 0.91 4.82 1.01 3.224.54 0.59 0.39 0.54 2 1.6 0.85 3 1.2 2 3 0.4 0.5 0.5 3 1.45 0.91 2 1.013.22 4.54 0.59 0.39 0.54 4 1.45 0.91 2 1.01 5 4.54 0.59 0.39 0.54 5 1.450.91 2 2 5 4.54 0.59 0.39 0.54 6 1.45 0.91 4.82 1.01 3.22 3 0.59 0.390.54 7 1.45 0.91 4.82 1.01 3.22 4 0.59 0.39 0.54 8 1.45 0.91 4.82 1.013.22 6 0.59 0.39 0.54 9 1.45 0.91 4.82 1.01 3.22 6 0.59 1 0.54 10 1.450.91 4.82 1.01 3.22 6 0.59 1 2 11 1.45 0.91 4.82 1.01 3.22 4.5 0.59 10.54 12 1.45 0.91 4.82 1.01 3.22 4.5 0.59 0.75 0.54 13 1.45 0.91 4.821.01 3.22 4.5 0.59 1.25 0.54 14 1.45 0.91 4.82 1.01 3.22 4.5 0.59 0.60.54 15 1.6 0.85 3 1.2 2 3 0.4 1 0.5 16 1.45 0.85 3 1.2 2 3 0.4 1 0.5 171.45 0.91 4.82 1.01 3.22 6 0.59 1 0.54 18 1.45 0.91 4.82 1.01 3.22 4.540.59 1 0.54 19 2.5 0.91 4.82 1.01 3.22 4.54 0.59 1 0.54 20 1.45 0.94 5.51.31 3.08 4 0.53 0.6 0.53 21 1.45 0.94 5.5 1.31 3.08 3.5 0.53 0.6 0.5322 1.45 0.94 5.5 1.31 3.08 3 0.53 0.6 0.53 23 1.45 0.94 5.5 1.31 3.08 20.53 0.6 0.53 24 1.75 0.85 5 1 3 4 0.4 0.25 0.5 25 2.5 0.85 5 1 3 4 0.40.25 0.5 26 2.5 0.85 5 1 1 4 0.4 0.25 0.5 27 2.5 0.85 5 0 0 4 0.4 0.250.5 28 2.5 0.85 5 0 0 4 0.4 0.25 0.5 29 2.8 0.8 6.5 0 0 3.7 0 0.25 0 302.5 0.9 5 1 1 4 0.4 0.4 0.5 31 2 0.9 5 1 1 4 0.4 0.4 0.5 32 1.75 0.9 5 11 4 0.4 0.4 0.5 33 1.5 0.9 5 1 1 4 0.4 0.4 0.5 34 1 0.9 5 1 1 4 0.4 0.40.5 35 1.5 1.13 5 1 1 5.81 0.4 0.4 0.5 36 1.07 1.13 5 1 1 5.71 0.4 0.40.5 37 0.65 1.33 5 1 1 5.66 0.4 1.3 0.5 38 0.64 1.32 5 1 1 7.36 0.4 0.40.5 39 0.65 1.5 5 1 1 5 0.4 1 0.5 40 0.5 2 5 1 1 5 0.4 1 0.5 41 0.5 1.55 1 1 5 0.4 1 0.5 42 0.25 1.5 5 1 1 5 0.4 1 0.5 43 0 1.5 5 1 1 5 0.4 10.5 44 1.1 0.65 0.5 0.7 1 3.5 0.5 2.5 0.5 45 1.1 0.65 1.5 0.7 1 2.5 0.52.5 0.5 46 1.1 0.65 3 0.7 1 2.5 0.5 2 0.5 47 1.1 0.65 3 0.7 0.35 2.5 0.52 0.07 48 0.8 0.95 1 0.7 1 3.5 0.5 2.5 0.5 49 0.8 0.95 0.5 0.7 1 3 0.52.5 0.5 50 0.8 0.95 0.5 0.7 1 4 0.5 2 0.5 51 0.8 0.95 2 0.7 1 3 0.5 2.50.5 52 0.8 0.95 0.5 1 1 1 0.5 2 0.5 53 0.8 0.95 0.5 1 1 1.5 0.5 1 0.5 540.2 1.5 0.5 0.78 0.68 2.67 0.44 0.45 0.36 55 0.2 2.3 0.5 0.75 0.7 5 0.443 0.36 56 0.2 2.1 0.5 0.75 0.7 5 0.44 3 0.36 57 0.2 1.8 0.5 0.75 0.7 50.44 3 0.36 58 0.2 1.6 0.5 0.75 0.7 5 0.44 3 0.36 59 0.3 1.25 0.75 1.1 13.8 0.65 0.65 0.5 60 0.3 1.15 0.75 1.1 1 3.8 0.65 0.65 0.5 61 0.3 0.950.75 1.1 1 3.8 0.65 0.65 0.5 62 0.3 1.75 1.75 1 1 3 0.6 0.6 0.5 63 0.31.1 1.75 1 1 3 0.6 0.6 0.5 64 0 1.2 5 1 1 3 0.65 0.65 0.5 65 0.1 1.2 5 11 3 0.65 1.3 0.5 66 0 1.4 5 1 1 3 0.65 0.65 0.5 67 0.1 1.4 5 1 1 3 0.651.3 0.5 68 0.1 1.1 3.5 0.75 0.75 2.75 0.5 0.5 0.5 69 0.4 1.3 3.5 0.750.75 2.75 0.5 0.5 0.5 70 1.25 0.95 5.88 1.16 1 4 0.55 0.44 0.56 71 0.41.35 7 1.1 1 3.5 0.5 0.5 0.5 72 0.1 1.35 7 1.1 1 3.5 0.5 0.65 0.5 73 01.6 5 1 1 5.7 0.65 0 0 74 0 1.85 5 1 1 5.7 0.65 0 0 75 0.6 1 14.25 1.1 14.5 0.5 0.5 0.5 76 0.9 1.1 14.25 1.1 1 3.5 0.5 0.5 0.5 77 0.75 1.0514.25 1.1 1 3.5 0.5 0.5 0.5 79 0.6 1 14.25 1.1 1 4.5 0.5 0.5 0.5 80 0.91.1 14.25 1.1 1 3.5 0.5 0.5 0.5 81 0.75 1.05 14.25 1.1 1 3.5 0.5 0.5 0.582 0.75 1.25 14.25 1.1 1 3.5 0.5 0.5 0.5 84 0.75 0.95 14.25 1.1 1 3.50.5 0.5 0.5 85 0.75 0.85 14.25 1.1 1 3.5 0.5 0.5 0.5 86 0.75 0.75 14.251.1 1 3.5 0.5 0.5 0.5

Thermodynamic Criteria

In some embodiments, the alloy can be fully described by thermodynamicmodels. Four thermodynamic modeling criteria can be used to define thealloys: 1) the maximum eutectic carbide/boride phase fraction, 2) theminimum temperature gap between the liquidus temperature of theaustenite and the formation temperature of the eutectic carbide/boridephase, 3) the minimum level of C in liquid, and 4) the presence of bothcarbides and borides at a temperature no less than 80K below theliquidus temperature of the austenite or ferrite matrix phase.

The first thermodynamic criterion can be the maximum eutectic carbideand/or boride phase fraction. This criterion is related to the tendencyfor a hardfacing alloy to stress crack. As the phase fraction of the sumof any eutectic carbides and borides increases, the tendency for stresscracking can increase. The maximum limit for eutectic carbides/boridesbefore stress cracking occurs has been determined experimentally to be15 volume % (or about 15 volume %). Eutectic carbides/borides aredefined as any carbide or boride phase which forms at a temperatureequivalent to or below the liquidus temperature of the austenite. Theeutectic carbide/boride phase fraction is defined as the sum total ofcarbides and borides which exist at 1300K (or about 1300K), which have aformation temperature at or below the liquidus temperature of theaustenite. In some embodiments, the maximum eutectic carbide/boridephase fraction can be 15 mole % (or about 15 mole %). In someembodiments, the maximum eutectic carbide/boride phase fraction can be10 mole % (or about 10 mole %). In some embodiments, the maximumeutectic carbide/boride phase fraction can be 5 mole % (or about 5 mole%).

The eutectic mole fraction will typically be highest in the un-dilutedstate, when the weld is re-applied over worn versions of itself at least3 successive times. In some embodiments, this first describedthermodynamic criterion can be met for a hardfacing alloy in theun-diluted state. The solidification diagram for one embodiment, Alloy86, is shown in FIG. 1 for the undiluted state. As shown the totaleutectic boride mole fraction (Cr₂B+Fe,Mo₃B₂) [102] is below 15%, and isat 14.2%.

The second thermodynamic criterion can be the grain boundary formationtemperature gap. This criterion relates to the tendency of the alloy tohot tear. As the temperature gap increases, the tendency to hot tear canincrease. It has been determined using experimental measurements that itmay be advantageous if the temperature gap does not exceed 80K (or about80K), which can thereby avoid hot tearing of the hardfacing material.The grain boundary formation temperature gap is defined as thedifference in temperature between the austenite or ferrite liquidustemperature and the highest temperature at which any eutectic carbide orboride exists. In some embodiments, the maximum grain boundary formationtemperature gap can be 80K (or about 80K). In some embodiments, themaximum grain boundary formation temperature gap can be 50K (or about50K). In some embodiments, the maximum grain boundary formationtemperature gap can be 0K (or about OK). As shown when comparing FIG. 2and FIG. 3, the initial solidifying matrix phase can either be ferriticor austenitic, and the grain boundary formation temperature gap ismeasured by using the highest formation temperature of either phase uponcooling from a liquid state.

The grain boundary formation temperature gap will typically be thelargest in the diluted state, when the weld is applied over baresubstrate material such as, for example, 41XX series or mild steels. Insome embodiments, this second thermodynamic criteria can be met for thehardfacing alloy in the fully diluted state. In typical weldingprocesses the diluted state can equate to 70% of the total alloy contentof the original wire chemistry and 30% of the total alloy content of thesubstrate. The solidification diagram for the exemplary embodiment,Alloy 86, is shown in FIG. 3 for the diluted state, when welding over4137 steel. As shown the grain boundary formation temperature gap [202]is 50K.

As shown in FIG. 2 and FIG. 3, the eutectic mole fraction for Alloy 86in the fully diluted state [201] is 7.8% and the grain boundaryformation temperature gap for the fully undiluted state [102] is 50K.Thus, Alloy 86 meets the thermodynamic criteria when both fully dilutedand fully undiluted.

Many alloys meet either the first thermodynamic criterion or the secondthermodynamic criterion but not both. Thus, computational modeling toevaluate extremely large compositional ranges can be used to design thistype of material as both criteria are inversely related. Generally, asthe eutectic carbide/boride phase fraction is decreased, the temperaturegap is increased, and vice versa. Thus, the compositional range ofalloys which simultaneously meet both these criteria is relativelynarrow and not intuitive. Some hardfacing materials will not form grainboundary carbides or borides and thus do not meet criterion 2. It hasbeen shown experimentally, that these alloys are highly susceptible tohot tearing.

The third thermodynamic criterion can be the minimum C level in theliquid. This criterion relates to the tendency for the hardfacing alloyto form significant fraction of martensite upon cooling and thus be hardand wear resistant. It has been determined experimentally that 0.5weight % C (or about 0.5 weight % C) or greater in the liquid can createa significantly martensitic matrix under typical hardfacing depositionconditions. The minimum C level in the liquid is defined as the lowestweight fraction of carbon in the liquid over temperature span where thealloy is 100% liquid and the liquidus temperature of the austenite.However, as martensitic formation is cooling rate dependent, thiscriterion does not guarantee the presence of martensite in the matrix inevery processing condition. In some embodiments, the minimum C level inthe liquid can be 0.5 weight % (or about 0.5 weight %) or greater. Insome embodiments, the minimum C level in the liquid can be 0.7 weight %(or about 0.7 weight %) or greater. In some embodiments, the minimum Clevel in the liquid can be 0.9 weight % (or about 0.9 weight %) orgreater.

The fourth thermodynamic criteria is that the alloy can form bothcarbides and borides, and the carbides can be thermodynamically stableat a temperature equal to or greater than 80K (or about 80K) below theliquidus temperature of the austenite or ferrite matrix phase. Thiscriterion relates to a hardbanding alloy's ability to be welded ontoexisting boron containing and/or carbon containing welds withoutexhibiting hot tearing or stress cracking.

Table 2 lists the thermodynamic properties for selected alloys evaluatedin this disclosure. All alloys in this table meet the four thermodynamiccriteria, as they all possess both carbides and borides at a temperatureequal to or greater than 80K below the liquidus temperature of theaustenite or ferrite matrix phase. Table 3 lists the compositions ifalloys which meet the thermodynamic criteria listed in this disclosure.

TABLE 2 Table of thermodynamic properties for selected alloycompositions Grain Boundary Eutectic Formation Alloy Mole FractionTemperature Gap % C in Liquid 86 - Undiluted 12.2% 50K 0.51% 86 - Dilute 7.8% 50K 0.52% M1  8.6% 30K 0.99% M2 11.6%  0K 0.77%

TABLE 3 Alloy chemistries in weight percent, balance Fe, for selectedalloys evaluated using thermodynamic models which meet thermodynamiccriteria Alloy B C Cr Mn Mo Nb Si Ti V W Zr M1 0.8 0.82 13.5 1.15 0.953.35 0.52 0.5 0.45 0 0 M2 0.8 0.82 13.75 1.15 0.95 3.35 0.52 0.5 0.45 00 M3 0.8 0.82 14 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M4 0.8 0.82 14.25 1.150.95 3.35 0.52 0.5 0.45 0 0 M5 0.8 0.82 14.5 1.15 0.95 3.35 0.52 0.50.45 0 0 M6 0.8 0.82 14.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M7 0.8 0.8215 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M8 0.8 0.84 13.5 1.15 0.95 3.35 0.520.5 0.45 0 0 M9 0.8 0.84 13.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M10 0.80.84 14 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M11 0.8 0.84 14.25 1.15 0.953.35 0.52 0.5 0.45 0 0 M12 0.8 0.84 14.5 1.15 0.95 3.35 0.52 0.5 0.45 00 M13 0.8 0.84 14.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M14 0.8 0.84 151.15 0.95 3.35 0.52 0.5 0.45 0 0 M15 0.8 0.86 13.5 1.15 0.95 3.35 0.520.5 0.45 0 0 M16 0.8 0.86 13.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M17 0.80.86 14 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M18 0.8 0.86 14.25 1.15 0.953.35 0.52 0.5 0.45 0 0 M19 0.8 0.86 14.5 1.15 0.95 3.35 0.52 0.5 0.45 00 M20 0.8 0.86 14.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M21 0.8 0.86 151.15 0.95 3.35 0.52 0.5 0.45 0 0 M22 0.8 0.88 13.5 1.15 0.95 3.35 0.520.5 0.45 0 0 M23 0.8 0.88 13.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M24 0.80.88 14 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M25 0.8 0.88 14.25 1.15 0.953.35 0.52 0.5 0.45 0 0 M26 0.8 0.88 14.5 1.15 0.95 3.35 0.52 0.5 0.45 00 M27 0.8 0.88 14.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M28 0.8 0.88 151.15 0.95 3.35 0.52 0.5 0.45 0 0 M29 0.8 0.9 13.5 1.15 0.95 3.35 0.520.5 0.45 0 0 M30 0.8 0.9 13.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M31 0.80.9 14 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M32 0.8 0.9 14.25 1.15 0.95 3.350.52 0.5 0.45 0 0 M33 0.8 0.9 14.5 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M340.8 0.9 14.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M35 0.8 0.9 15 1.15 0.953.35 0.52 0.5 0.45 0 0 M36 0.8 0.92 13.5 1.15 0.95 3.35 0.52 0.5 0.45 00 M37 0.8 0.92 13.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M38 0.8 0.92 141.15 0.95 3.35 0.52 0.5 0.45 0 0 M39 0.8 0.92 14.25 1.15 0.95 3.35 0.520.5 0.45 0 0 M40 0.8 0.92 14.5 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M41 0.80.92 14.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M42 0.8 0.92 15 1.15 0.953.35 0.52 0.5 0.45 0 0 M43 0.8 0.94 13.5 1.15 0.95 3.35 0.52 0.5 0.45 00 M44 0.8 0.94 13.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M45 0.8 0.94 141.15 0.95 3.35 0.52 0.5 0.45 0 0 M46 0.8 0.94 14.25 1.15 0.95 3.35 0.520.5 0.45 0 0 M47 0.8 0.94 14.5 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M48 0.80.94 14.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M49 0.8 0.94 15 1.15 0.953.35 0.52 0.5 0.45 0 0 M50 0.8 0.96 13.5 1.15 0.95 3.35 0.52 0.5 0.45 00 M51 0.8 0.96 13.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M52 0.8 0.96 141.15 0.95 3.35 0.52 0.5 0.45 0 0 M53 0.8 0.96 14.25 1.15 0.95 3.35 0.520.5 0.45 0 0 M54 0.8 0.96 14.5 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M55 0.80.96 14.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M56 0.8 0.96 15 1.15 0.953.35 0.52 0.5 0.45 0 0 M57 0.8 0.98 13.5 1.15 0.95 3.35 0.52 0.5 0.45 00 M58 0.8 0.98 13.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M59 0.8 0.98 141.15 0.95 3.35 0.52 0.5 0.45 0 0 M60 0.8 0.98 14.25 1.15 0.95 3.35 0.520.5 0.45 0 0 M61 0.8 0.98 14.5 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M62 0.80.98 14.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M63 0.8 0.98 15 1.15 0.953.35 0.52 0.5 0.45 0 0 M64 0.8 1 13.5 1.15 0.95 3.35 0.52 0.5 0.45 0 0M65 0.8 1 13.75 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M66 0.8 1 14 1.15 0.953.35 0.52 0.5 0.45 0 0 M67 0.8 1 14.25 1.15 0.95 3.35 0.52 0.5 0.45 0 0M68 0.8 1 14.5 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M69 0.8 1 14.75 1.150.95 3.35 0.52 0.5 0.45 0 0 M70 0.8 1 15 1.15 0.95 3.35 0.52 0.5 0.45 00 M71 0.8 1.02 13.5 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M72 0.8 1.02 13.751.15 0.95 3.35 0.52 0.5 0.45 0 0 M73 0.8 1.02 14 1.15 0.95 3.35 0.52 0.50.45 0 0 M74 0.8 1.02 14.25 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M75 0.81.02 14.5 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M76 0.8 1.02 14.75 1.15 0.953.35 0.52 0.5 0.45 0 0 M77 0.8 1.02 15 1.15 0.95 3.35 0.52 0.5 0.45 0 0M78 0.8 1.04 13.5 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M79 0.8 1.04 13.751.15 0.95 3.35 0.52 0.5 0.45 0 0 M80 0.8 1.04 14 1.15 0.95 3.35 0.52 0.50.45 0 0 M81 0.8 1.04 14.25 1.15 0.95 3.35 0.52 0.5 0.45 0 0 M82 1.1 0.95 0 1 2.5 0.5 1 0.5 0 0 M83 1.1 0.9 5 0 1 3 0.5 1 0.5 0 0 M84 1.1 0.9 50 1 3.5 0.5 1 0.5 0 0 M85 1.1 0.9 5 0 1 4 0.5 1 0.5 0 0 M86 1.1 0.9 5 01 5 0.5 0 0.5 0 0 M87 0.7 0.8 14.25 1.1 1 3.5 0.5 0.5 0.5 0 0 M88 0.70.9 14.25 1.1 1 3.5 0.5 0.5 0.5 0 0 M89 0.7 1 14.25 1.1 1 3.5 0.5 0.50.5 0 0 M90 0.8 0.9 14.25 1.1 1 3.5 0.5 0.5 0.5 0 0 M91 0.8 1 14.25 1.11 3.5 0.5 0.5 0.5 0 0 M92 0.9 0.9 14.25 1.1 1 3.5 0.5 0.5 0.5 0 0 M930.9 1 14.25 1.1 1 3.5 0.5 0.5 0.5 0 0 M94 0.8 0.95 1 0 1 3 0.5 0 0.5 0 0M95 0.8 0.95 2 0 1 2.5 0.5 1.5 0.5 0 0 M96 0.8 0.95 2 0 1 4 0.5 0.5 0.50 0 M97 0.8 0.95 2.5 0 1 3.5 0.5 0.5 0.5 0 0 M98 0.8 0.95 2.5 0 1 4 0.50.5 0.5 0 0 M99 0.8 0.95 2.5 0 1 4.5 0.5 0.5 0.5 0 0 M100 0.8 0.95 2.5 01 5 0.5 1 0.5 0 0 M101 0.8 0.95 3 0 1 3 0.5 0.5 0.5 0 0 M102 0.8 0.95 30 1 3.5 0.5 0.5 0.5 0 0 M103 0.8 0.95 3 0 1 4 0.5 0.5 0.5 0 0 M104 0.80.95 3 0 1 4.5 0.5 0.5 0.5 0 0 M105 0.8 0.95 3 0 1 4.5 0.5 1 0.5 0 0M106 0.8 0.95 3.5 0 1 3 0.5 0.5 0.5 0 0 M107 0.8 0.95 3.5 0 1 3.5 0.50.5 0.5 0 0 M108 0.8 0.95 3.5 0 1 4 0.5 0.5 0.5 0 0 M109 0.8 0.95 3.5 01 4.5 0.5 0.5 0.5 0 0 M110 0.8 0.95 4 0 1 2.5 0.5 0.5 0.5 0 0 M111 0.80.95 4 0 1 3 0.5 0.5 0.5 0 0 M112 0.8 0.95 4 0 1 3.5 0.5 0 0.5 0 0 M1130.8 0.95 4 0 1 3.5 0.5 0.5 0.5 0 0 M114 0.8 0.95 4 0 1 4 0.5 0 0.5 0 0M115 0.8 0.95 4 0 1 4 0.5 0.5 0.5 0 0 M116 0.8 0.95 4 0 1 4.5 0.5 0 0.50 0 M117 0.8 0.95 4 0 1 4.5 0.5 0.5 0.5 0 0 M118 0.8 0.95 4 0 1 5 0.5 00.5 0 0 M119 0.8 0.95 4.5 0 1 2.5 0.5 0 0.5 0 0 M120 0.8 0.95 4.5 0 12.5 0.5 0.5 0.5 0 0 M121 0.8 0.95 4.5 0 1 3 0.5 0 0.5 0 0 M122 0.8 0.954.5 0 1 3 0.5 0.5 0.5 0 0 M123 0.8 0.95 4.5 0 1 3.5 0.5 0 0.5 0 0 M1240.8 0.95 4.5 0 1 3.5 0.5 0.5 0.5 0 0 M125 0.8 0.95 4.5 0 1 4 0.5 0 0.5 00 M126 0.8 0.95 4.5 0 1 4 0.5 0.5 0.5 0 0 M127 0.8 0.95 4.5 0 1 4.5 0.50 0.5 0 0 M128 0.8 0.95 4.5 0 1 4.5 0.5 0.5 0.5 0 0 M129 0.8 0.95 4.5 01 5 0.5 0 0.5 0 0 M130 0.8 0.95 4.5 0 1 5.5 0.5 0 0.5 0 0 M131 0.8 0.955 0 1 2.5 0.5 0 0.5 0 0 M132 0.8 0.95 5 0 1 2.5 0.5 0.5 0.5 0 0 M133 0.80.95 5 0 1 3 0.5 0 0.5 0 0 M134 0.8 0.95 5 0 1 3 0.5 0.5 0.5 0 0 M1350.8 0.95 5 0 1 3.5 0.5 0 0.5 0 0 M136 0.8 0.95 5 0 1 3.5 0.5 0.5 0.5 0 0M137 0.8 0.95 5 0 1 4 0.5 0 0.5 0 0 M138 0.8 0.95 5 0 1 4 0.5 0.5 0.5 00 M139 0.8 0.95 5 0 1 4.5 0.5 0 0.5 0 0 M140 0.8 0.95 5 0 1 4.5 0.5 0.50.5 0 0 M141 0.8 0.95 5 0 1 5 0.5 0 0.5 0 0 M142 0.8 0.95 5 0 1 5.5 0.50 0.5 0 0 M143 0.6 0.8 10 0 0 3.5 0 0 0 0 0 M144 0.6 0.8 12 0 0 3.5 0 00 0 0 M145 0.6 0.8 14 0 0 3.5 0 0 0 0 0 M146 0.6 0.8 16 0 0 3.5 0 0 0 00 M147 0.6 0.8 18 0 0 3.5 0 0 0 0 0 M148 0.6 0.8 20 0 0 3.5 0 0 0 0 0M149 0.6 0.8 22 0 0 3.5 0 0 0 0 0 M150 0.6 1 10 0 0 3.5 0 0 0 0 0 M1510.6 1 12 0 0 3.5 0 0 0 0 0 M152 0.6 1 14 0 0 3.5 0 0 0 0 0 M153 0.6 1 160 0 3.5 0 0 0 0 0 M154 0.6 1 18 0 0 3.5 0 0 0 0 0 M155 0.6 1.2 10 0 03.5 0 0 0 0 0 M156 0.6 1.2 12 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1.2 16 1 1 00.5 0 10 0 0 M1785 0.9 1.3 12 1 1 0 0.5 0 6 0 0 M1786 0.9 1.3 12 1 1 00.5 0 7 0 0 M1787 0.9 1.3 12 1 1 0 0.5 0 8 0 0 M1788 0.9 1.3 12 1 1 00.5 0 9 0 0 M1789 0.9 1.3 12 1 1 0 0.5 0 10 0 0 M1790 0.9 1.3 14 1 1 00.5 0 7 0 0 M1791 0.9 1.3 14 1 1 0 0.5 0 8 0 0 M1792 0.9 1.3 14 1 1 00.5 0 9 0 0 M1793 0.9 1.3 14 1 1 0 0.5 0 10 0 0 M1794 0.9 1.3 16 1 1 00.5 0 8 0 0 M1795 0.9 1.3 16 1 1 0 0.5 0 9 0 0 M1796 0.9 1.3 16 1 1 00.5 0 10 0 0 M1797 0.9 1.4 12 1 1 0 0.5 0 5 0 0 M1798 0.9 1.4 12 1 1 00.5 0 6 0 0 M1799 0.9 1.4 12 1 1 0 0.5 0 7 0 0 M1800 0.9 1.4 12 1 1 00.5 0 8 0 0 M1801 0.9 1.4 12 1 1 0 0.5 0 9 0 0 M1802 0.9 1.4 12 1 1 00.5 0 10 0 0 M1803 0.9 1.4 14 1 1 0 0.5 0 6 0 0 M1804 0.9 1.4 14 1 1 00.5 0 7 0 0 M1805 0.9 1.4 14 1 1 0 0.5 0 8 0 0 M1806 0.9 1.4 14 1 1 00.5 0 9 0 0 M1807 0.9 1.4 14 1 1 0 0.5 0 10 0 0 M1808 0.9 1.4 16 1 1 00.5 0 8 0 0 M1809 0.9 1.4 16 1 1 0 0.5 0 9 0 0 M1810 0.9 1.4 16 1 1 00.5 0 10 0 0 M1811 0.9 1.5 12 1 1 0 0.5 0 6 0 0 M1812 0.9 1.5 12 1 1 00.5 0 7 0 0 M1813 0.9 1.5 12 1 1 0 0.5 0 8 0 0 M1814 0.9 1.5 12 1 1 00.5 0 9 0 0 M1815 0.9 1.5 12 1 1 0 0.5 0 10 0 0 M1816 0.9 1.5 14 1 1 00.5 0 7 0 0 M1817 0.9 1.5 14 1 1 0 0.5 0 8 0 0 M1818 0.9 1.5 14 1 1 00.5 0 9 0 0 M1819 0.9 1.5 14 1 1 0 0.5 0 10 0 0 M1820 0.9 1.5 16 1 1 00.5 0 9 0 0 M1821 0.9 1.5 16 1 1 0 0.5 0 10 0 0 M1822 0.9 1.6 12 1 1 00.5 0 6 0 0 M1823 0.9 1.6 12 1 1 0 0.5 0 7 0 0 M1824 0.9 1.6 12 1 1 00.5 0 8 0 0 M1825 0.9 1.6 12 1 1 0 0.5 0 9 0 0 M1826 0.9 1.6 12 1 1 00.5 0 10 0 0 M1827 0.9 1.6 14 1 1 0 0.5 0 7 0 0 M1828 0.9 1.6 14 1 1 00.5 0 8 0 0 M1829 0.9 1.6 14 1 1 0 0.5 0 9 0 0 M1830 0.9 1.6 14 1 1 00.5 0 10 0 0 M1831 0.9 1.6 16 1 1 0 0.5 0 9 0 0 M1832 0.9 1.6 16 1 1 00.5 0 10 0 0 M1833 0.9 1.7 12 1 1 0 0.5 0 7 0 0 M1834 0.9 1.7 12 1 1 00.5 0 8 0 0 M1835 0.9 1.7 12 1 1 0 0.5 0 9 0 0 M1836 0.9 1.7 12 1 1 00.5 0 10 0 0 M1837 0.9 1.7 14 1 1 0 0.5 0 8 0 0 M1838 0.9 1.7 14 1 1 00.5 0 9 0 0 M1839 0.9 1.7 14 1 1 0 0.5 0 10 0 0 M1840 0.9 1.7 16 1 1 00.5 0 9 0 0 M1841 0.9 1.7 16 1 1 0 0.5 0 10 0 0 M1842 0.9 1.8 12 1 1 00.5 0 7 0 0 M1843 0.9 1.8 12 1 1 0 0.5 0 8 0 0 M1844 0.9 1.8 12 1 1 00.5 0 9 0 0 M1845 0.9 1.8 12 1 1 0 0.5 0 10 0 0 M1846 0.9 1.8 14 1 1 00.5 0 8 0 0 M1847 0.9 1.8 14 1 1 0 0.5 0 9 0 0 M1848 0.9 1.8 14 1 1 00.5 0 10 0 0 M1849 0.9 1.8 16 1 1 0 0.5 0 10 0 0 M1850 0.9 1.9 12 1 1 00.5 0 8 0 0 M1851 0.9 1.9 12 1 1 0 0.5 0 9 0 0 M1852 0.9 1.9 12 1 1 00.5 0 10 0 0 M1853 0.9 1.9 14 1 1 0 0.5 0 9 0 0 M1854 0.9 1.9 14 1 1 00.5 0 10 0 0 M1855 0.9 1.9 16 1 1 0 0.5 0 10 0 0 M1856 0.9 2 12 1 1 00.5 0 10 0 0 M1857 0.9 2 14 1 1 0 0.5 0 10 0 0

Microstructural Criteria

In some embodiments, the alloy can be described by the microstructuralfeatures it possesses. The microstructural features can be 1) martensiteis present in the matrix, and 2) the grain boundary carbide and orboride volume fraction is below 15% (or below about 15%) but greaterthan 0% (or greater than about 0%), and 3) both carbides and borides arepresent. The thermodynamic criteria can be designed in such a way as toencourage this type of microstructure. An example of the disclosedmicrostructure is shown in FIG. 4. The microstructure has a martensiticmatrix [401] embedded with chromium-rich eutectic borides [402] andniobium rich primary carbides [403].

In some embodiments, the matrix can be at least 10% (or at least about10%) by volume martensite. In some embodiments, the matrix can be atleast 50% (or at least about 50%) by volume martensite. In someembodiments, the matrix can be at least 90% (or at least about 90%) byvolume martensite.

In some embodiments, the sum of grain boundary carbides and/or boridescan be below 15 volume % (or below about 15 volume %). In someembodiments, the sum of grain boundary carbides and/or borides can bebelow 10 volume % (or below about 10 volume %). In some embodiments, thesum of grain boundary carbides and/or borides can be below 5 volume %(or below about 5 volume %).

In some embodiments, both carbides and borides can be present.

Performance Criteria

In some embodiments, the alloy can be fully described by the performancecharacteristics. Four performance characteristics can be used to definethe alloy 1) minimum hardness, 2) minimum wear resistance ascharacterized using ASTM G65 Procedure A, 3) the lack of hot tearingwhen welded using typical hardfacing procedures, 4) the lack of stresscracking when welded using typical hardfacing procedures, and 5)exhibiting characteristics 1-4 when re-build onto existing weldscontaining carbon and/or boron. Criteria 1 and 2 are common amongsthardfacing alloys, however alloys exhibiting all four performancecriteria are very rare. Furthermore, alloys which exhibit all fiveperformance criteria are not currently known to the state of the art.

Criteria 1 and 2 relate to the intended function of the hardfacinglayer, to provide a level of protection against wear to a component.Generally, increased hardness and increased wear resistance can beadvantageous. In some embodiments, the minimum hardness of the weld canbe 50 HRC (or about 50 HRC). In some embodiments, the minimum hardnessof the weld can be 55 HRC (Or about 55 HRC). In some embodiments, theminimum hardness of the weld can be 57 HRC (or about 57 HRC).

In some embodiments, the wear resistance can be characterized by ASTMG65A dry sand abrasion testing, hereby incorporated by reference in itsentirety, where a lower mass loss signifies increased durability. Insome embodiments, the maximum mass loss under ASTM G65A testing can be0.5 g (or about 0.5 g) lost. In some embodiments, the maximum mass lossunder ASTM G65A testing can be 0.3 g (or about 0.3 g) lost. In someembodiments, the maximum mass loss under ASTM G65A testing can be 0.2 g(or about 0.2 g) lost.

Criteria 3 and 4 relate to different mechanisms in cracking which areknown to occur in hardfacing. The presence of any cracks (whethercreated through stress crack mechanisms or hot tear mechanism) cancreate a weld which falls outside of the performance criteria of thisdisclosure, and is generally undesirable in the field of hardfacing.There are several methods which are known by those skilled in the art todetect cracks in hardfacing welds, such as the dye penetrant test andthe magnetic particle inspection. The presence of any cracks revealedthrough these or equivalent techniques represents a weld which fallsoutside of the performance criteria of this disclosure

Criteria 5 relates to an alloys ability to be welded over existing andpotentially dissimilar hardbands. This criterion has utility for theoilfield industry due to the variety of hardbanding alloys currentlyused and used in the past coupled with the lack of tracking of hardbandsonto the drill pipe. In any welding process, there is a certain amountof dilution of the weld material with the base material. As an originalsingle layer weld overlay, the weld material is diluted with the tooljoint chemistry, which is typically a 41XX series steel alloy. However,during a re-build, even when the previous hardband is worn flush withthe tool joint, the 2^(nd) layer hardband can be diluted with the worn1^(st) layer hardband chemistry. When using the MIG welding process,which is common to hardbanding and other forms of hardfacing, thedilution is about 30%. Thus, the 2^(nd) layer hardband can be composedof 70% the weld wire chemistry and 30% the chemistry of the originalhardband. It is common for hardbanding alloys to have weld wirechemistries containing C+B in the range of 1-2%. Thus, it is common todilute a new overlay with 0.3-0.6 wt. % C+B. In one embodiment, thealloys of this patent can accommodate 0.3% (or about 0.3%) C+B dilutioninto the re-building weld bead without hot tearing or stress cracking.In some embodiments, the alloys of this patent can accommodate 0.45% (orabout 0.45%) C+B dilution into the re-building weld bead without hottearing or stress cracking. In some embodiments, the alloys of thispatent can accommodate 0.6% (or about 0.6%) C+B dilution into there-building weld bead without hot tearing or stress cracking.

Table 4 shows select experimental data for the alloy manufactured intoingot form for microstructural and hardness analysis and/or manufacturedinto welding wire for trials. Complete data is not available for allcompositions as some alloys in which thermodynamic or microstructuraldata indicated poor performance where not selected for welding trials.This table helps demonstrate the uniqueness of these alloys as only 3out of 86 (3.6%) of the alloys evaluated met the specified performancecriteria. Table 1 lists the chemistry of all the alloys evaluated andshown in Table 4.

TABLE 4 Performance Results from Experimental Alloys Selected forWelding Trials GB Borides, Stress Hot ALLOY Carbides Cracking TearingHardness 1 >20%*  YES* NO 60 2 >20%*  YES* NO 60 44  41* 45  30* 46  41*47  31* 48 0%   40* 49 0%   47* 50 0%   46* 51  15-20%  41* 52 54 53 0%*57 54 0%* NO YES* 64 58 0%* NO YES* 61 59 NO YES* 50 60 NO YES* 49 61 14* 62 NO YES* 62 63 NO YES* 49 64 0%* NO YES* 55 65 0%* NO YES* 50 660%* 52 67 0%* 58 68 0%* 56 69 0%* NO YES* 59 70 15-20%*  YES* NO 60 72NO YES* N/A 74 YES* NO N/A 76 0%* NO YES* 63 79 1-5% NO YES* 60 80 YES*NO N/A 81 1-5% YES* NO 56 82 YES* NO N/A 84 NO NO 56 85 NO NO 60 86 1-5%NO NO 60 *denotes criteria which do not meet either a microstructuralembodiment or performance embodiment of this disclosure

EXAMPLES

The following examples are intended to be illustrative and non-limiting:

Example 1

This example illustrates weld testing designing to simulate hardbandapplication and re-application over existing worn layers containingcarbon and boron. It was conducted using Alloy #84. A standard 4137steel 6⅝″ tool joint was used as the base material. Three slightlyoverlapping bands were initially applied onto the tool joint to create acontinuous overlay 3″ wide and 3.5/32″ thick along the outercircumference of the joint. The following weld parameters were used todeposit the 1^(st) and 2^(nd) layers:

Amps: 265

Volts: 29

Rotation: 2 min 56 sec

Oscillation: 1″

StickOut: 1⅛″

Overlap: ⅛″

PreHeat: 420° F.

Shielding Gas: Argon

Wire Feed: 250

After the deposition of the 1^(st) layer, a 2^(nd) hardfacing layer wasdeposited directly on top of the 1^(st), resulting in a weld bead of6.5/32″ of total thickness. No hot tears or stress cracks were observedusing dye penetrant inspection.

Examples 2-3

These examples illustrate weld testing designing to simulate hardbandapplication and re-application over existing worn layers containingcarbon and boron. Similar weld testing was conducted using similar weldparameters for both #85 and #86 alloy. No hot tears or stress crackswere observed using dye penetrant inspection after 2 consecutive layerswere welded for either alloy.

Example 4

The following example illustrates weld testing designed to simulaterepairing commonly occurring weld imperfections, and representsconditions where stress cracking is highly likely in typical hardfacingmaterials. Alloy #86 was deposited as a single layer overlay usingsimilar parameters shown in Example 1. However, the welding was stoppedand re-started intentionally to produce small gaps in the overlay. 5total gaps were left in the original overlay. The joint was allowed tocool to 500° F. and two of the gaps were filled in by depositing a smallweld overlay over the gap. After welding the 1^(st) two patches thejoint was then allowed to cool to 480° F., and two of the gaps werefilled in with a patch repair. After welding the third patch, the jointwas allowed to cool to 450° F. before applying a fourth patch. Afterwelding the fourth patch, the joint was allowed to cool to 450° F.before applying a final patch. No stress cracks or hot tears werecreated in the weld as a result of filling the 5 gaps with weld patchrepairs.

TABLE 5 Glow discharge spectrometer readings for weld wires which meteither microstructural criteria, performance criteria, or both Alloy B CCr Mn Mo Nb Si Ti V 79 0.519 0.918 15.6 1.1 1.02 4.05 0.586 0.393 0.44680 0.689 0.939 14.4 1.06 0.853 3 0.533 0.39 0.441 81 0.585 0.888 14.71.07 0.932 3.12 0.527 0.395 0.453 82 0.596 1.07 14.2 1.07 0.922 2.990.524 0.39 0.398 84 0.684 0.681 16.1 1.09 1.02 3.22 0.568 0.846 0.463 850.655 0.753 15.5 1.07 0.964 3.02 0.574 0.576 0.455 86 0.605 0.782 14.41.05 0.885 3.05 0.554 0.522 0.429

Applications and Processes for Use:

Embodiments of alloys disclosed herein can be used in a variety ofapplications and industries. Some non-limiting examples of applicationsof use include:

Surface mining applications including but not limited to the followingcomponents and coatings for the following components: wear resistantsleeves and/or wear resistant hardfacing for slurry pipelines, mud pumpcomponents including pump housing or impeller or hardfacing for mud pumpcomponents, ore feed chute components including chute blocks orhardfacing of chute blocks, separation screens including but not limitedto rotary breaker screens, banana screens, and shaker screens, linersfor autogenous grinding mills and semi-autogenous grinding mills, groundengaging tools and hardfacing for ground engaging tools, wear plate forbuckets and dumptruck liners, heel blocks and hardfacing for heel blockson mining shovels, grader blades and hardfacing for grader blades,stacker reclaimers, siazer crushers, general wear packages for miningcomponents and other communition components.

Upstream oil and gas applications including but not limited to thefollowing components and coatings for the following components: Downholecasing and downhole casing, drill pipe and coatings for drill pipeincluding hardbanding, mud management components, mud motors, frackingpump sleeves, fracking impellers, fracking blender pumps, stop collars,drill bits and drill bit components, directional drilling equipment andcoatings for directional drilling equipment including stabilizers andcentralizers, blow out preventers and coatings for blow out preventersand blow out preventer components including the shear rams, oil countrytubular goods and coatings for oil country tubular goods.

Downstream oil and gas applications including but not limited to thefollowing components and coatings for the following components: Processvessels and coating for process vessels including steam generationequipment, amine vessels, distillation towers, cyclones, catalyticcrackers, general refinery piping, corrosion under insulationprotection, sulfur recovery units, convection hoods, sour stripperlines, scrubbers, hydrocarbon drums, and other refinery equipment andvessels.

Pulp and paper applications including but not limited to the followingcomponents and coatings for the following components: Rolls used inpaper machines including yankee dryers and other dryers, calendar rolls,machine rolls, press rolls, digesters, pulp mixers, pulpers, pumps,boilers, shredders, tissue machines, roll and bale handling machines,doctor blades, evaporators, pulp mills, head boxes, wire parts, pressparts, M.G. cylinders, pope reels, winders, vacuum pumps, deflakers, andother pulp and paper equipment.

Power generation applications including but not limited to the followingcomponents and coatings for the following components: boiler tubes,precipitators, fireboxes, turbines, generators, cooling towers,condensers, chutes and troughs, augers, bag houses, ducts, ID fans, coalpiping, and other power generation components.

Agriculture applications including but not limited to the followingcomponents and coatings for the following components: chutes, basecutter blades, troughs, primary fan blades, secondary fan blades, augersand other agricultural applications.

Construction applications including but not limited to the followingcomponents and coatings for the following components: cement chutes,cement piping, bag houses, mixing equipment and other constructionapplications.

Machine element applications including but not limited to the followingcomponents and coatings for the following components: Shaft journals,paper rolls, gear boxes, drive rollers, impellers, general reclamationand dimensional restoration applications and other machine elementapplications.

Steel applications including but not limited to the following componentsand coatings for the following components: cold rolling mills, hotrolling mills, wire rod mills, galvanizing lines, continue picklinglines, continuous casting rolls and other steel mill rolls, and othersteel applications.

Embodiments of alloys disclosed herein can be produced and or depositedin a variety of techniques effectively. Some non-limiting examples ofprocesses include:

Thermal spray process including but not limited to those using a wirefeedstock such as twin wire arc, spray, high velocity arc spray,combustion spray and those using a powder feedstock such as highvelocity oxygen fuel, high velocity air spray, plasma spray, detonationgun spray, and cold spray. Wire feedstock can be in the form of a metalcore wire, solid wire, or flux core wire. Powder feedstock can be eithera single homogenous alloy or a combination of multiple alloy powderwhich result in the desired chemistry when melted together.

Welding processes including but not limited to those using a wirefeedstock including but not limited to metal inert gas (MIG) welding,tungsten inert gas (TIG) welding, arc welding, submerged arc welding,open arc welding, bulk welding, laser cladding, and those using a powderfeedstock including but not limited to laser cladding and plasmatransferred arc welding. Wire feedstock can be in the form of a metalcore wire, solid wire, or flux core wire. Powder feedstock can be eithera single homogenous alloy or a combination of multiple alloy powderwhich result in the desired chemistry when melted together.

Casting processes including but not limited to processes typical toproducing cast iron including but not limited to sand casting, permanentmold casting, chill casting, investment casting, lost foam casting, diecasting, centrifugal casting, glass casting, slip casting and processtypical to producing wrought steel products including continuous castingprocesses.

Post processing techniques including but not limited to but not limitedto rolling, forging, surface treatments such as carburizing, nitriding,carbonitriding, heat treatments including but not limited toaustenitizing, normalizing, annealing, stress relieving, tempering,aging, quenching, cryogenic treatments, flame hardening, inductionhardening, differential hardening, case hardening, decarburization,machining, grinding, cold working, work hardening, and welding.

One of the more applicable uses of this technology is in applicationswhere coatings are deposited on-site, in the field, or in locationswhere proper ventilation, dust collection, and other safety measurescannot be easily met. Some well-known non-limiting examples of theseapplications include power generation applications such as the coatingof boiler tubes, upstream refinery applications such as the coating ofrefinery vessels, and pulp and paper applications such as the coatingand grinding of yankee dryers.

From the foregoing description, it will be appreciated that an inventiveproduct and approaches for crack resistant hardbanding alloys aredisclosed. While several components, techniques and aspects have beendescribed with a certain degree of particularity, it is manifest thatmany changes can be made in the specific designs, constructions andmethodology herein above described without departing from the spirit andscope of this disclosure.

Certain features that are described in this disclosure in the context ofseparate implementations can also be implemented in combination in asingle implementation. Conversely, various features that are describedin the context of a single implementation can also be implemented inmultiple implementations separately or in any suitable subcombination.Moreover, although features may be described above as acting in certaincombinations, one or more features from a claimed combination can, insome cases, be excised from the combination, and the combination may beclaimed as any subcombination or variation of any subcombination.

Moreover, while methods may be depicted in the drawings or described inthe specification in a particular order, such methods need not beperformed in the particular order shown or in sequential order, and thatall methods need not be performed, to achieve desirable results. Othermethods that are not depicted or described can be incorporated in theexample methods and processes. For example, one or more additionalmethods can be performed before, after, simultaneously, or between anyof the described methods. Further, the methods may be rearranged orreordered in other implementations. Also, the separation of varioussystem components in the implementations described above should not beunderstood as requiring such separation in all implementations, and itshould be understood that the described components and systems cangenerally be integrated together in a single product or packaged intomultiple products. Additionally, other implementations are within thescope of this disclosure.

Conditional language, such as “can,” “could,” “might,” or “may,” unlessspecifically stated otherwise, or otherwise understood within thecontext as used, is generally intended to convey that certainembodiments include or do not include, certain features, elements,and/or steps. Thus, such conditional language is not generally intendedto imply that features, elements, and/or steps are in any way requiredfor one or more embodiments.

Conjunctive language such as the phrase “at least one of X, Y, and Z,”unless specifically stated otherwise, is otherwise understood with thecontext as used in general to convey that an item, term, etc. may beeither X, Y, or Z. Thus, such conjunctive language is not generallyintended to imply that certain embodiments require the presence of atleast one of X, at least one of Y, and at least one of Z.

Language of degree used herein, such as the terms “approximately,”“about,” “generally,” and “substantially” as used herein represent avalue, amount, or characteristic close to the stated value, amount, orcharacteristic that still performs a desired function or achieves adesired result. For example, the terms “approximately”, “about”,“generally,” and “substantially” may refer to an amount that is withinless than or equal to 10% of, within less than or equal to 5% of, withinless than or equal to 1% of, within less than or equal to 0.1% of, andwithin less than or equal to 0.01% of the stated amount. If the statedamount is 0 (e.g., none, having no), the above recited ranges can bespecific ranges, and not within a particular % of the value. Forexample, within less than or equal to 10 wt./vol. % of, within less thanor equal to 5 wt./vol. % of, within less than or equal to 1 wt./vol. %of, within less than or equal to 0.1 wt./vol. % of, and within less thanor equal to 0.01 wt./vol. % of the stated amount.

Some embodiments have been described in connection with the accompanyingdrawings. The figures are drawn to scale, but such scale should not belimiting, since dimensions and proportions other than what are shown arecontemplated and are within the scope of the disclosed inventions.Distances, angles, etc. are merely illustrative and do not necessarilybear an exact relationship to actual dimensions and layout of thedevices illustrated. Components can be added, removed, and/orrearranged. Further, the disclosure herein of any particular feature,aspect, method, property, characteristic, quality, attribute, element,or the like in connection with various embodiments can be used in allother embodiments set forth herein. Additionally, it will be recognizedthat any methods described herein may be practiced using any devicesuitable for performing the recited steps.

While a number of embodiments and variations thereof have been describedin detail, other modifications and methods of using the same will beapparent to those of skill in the art. Accordingly, it should beunderstood that various applications, modifications, materials, andsubstitutions can be made of equivalents without departing from theunique and inventive disclosure herein or the scope of the claims.

What is claimed is:
 1. A metal alloy composition, comprising: an Fe-based alloy comprising alloying elements of: boron; carbon; chromium; and niobium, titanium and/or vanadium; wherein the maximum eutectic carbide/boride phase fraction of the alloy is about 15 mole %; wherein the maximum grain boundary formation temperature gap of the alloy is about 80K; wherein the minimum carbon level in the liquid is about 0.5 wt. %; and wherein the alloy comprises both carbides and borides, and the carbides are thermodynamically stable at a temperature equal to or greater than about 80K below the liquid temperature of the austenite or ferrite matrix phase.
 2. The metal alloy composition of claim 1, wherein the alloy is primarily martensitic.
 3. The metal alloy composition of claim 1, wherein carbide and boride precipitates do not exceed about 15 volume %.
 4. The metal alloy composition of claim 1, wherein the alloy is provided as a hardfacing weld overlay.
 5. The metal alloy composition of claim 4, wherein the alloy is provided as a single layer onto a component.
 6. The metal alloy composition of claim 4, wherein the alloy is provided as multiple layers over a worn hardfacing layer.
 7. A work piece having at least a portion of its surface covered by a layer, wherein the layer comprises: an alloy having a macro-hardness of 50 HRC or greater, the alloy containing both carbides and borides; and wherein the alloy comprises a volume fraction of less than 10% eutectic carbides and/or borides.
 8. The work piece of claim 7, wherein the volume fraction of eutectic carbide and/or borides is greater than 0%.
 9. The work piece of claim 7, wherein a microstructure of the alloy comprises primary Nb and/or Ti rich carbides.
 10. The work piece of claim 7, wherein a microstructure of the alloy comprises eutectic Cr rich borides.
 11. The work piece of claim 7, wherein the alloy has high abrasion resistance as characterized by an ASTM G65A mass loss of less than 0.5 grams.
 12. The work piece of claim 7, wherein the alloy comprises Fe and, in wt. %: B: 0.6-0.9; C: 0.75-1.25; Cr: 14.25-26; and Nb+Ti+V: 3.5-4.5.
 13. The work piece of claim 12, wherein the alloy further comprises, in wt. %: Mn: about 1.1; Mo: about 1; and Si: about 0.5.
 14. A method of forming a coated workpiece comprising: depositing an alloy layer on at least a portion of the workpiece wherein the alloy layer comprises the following thermodynamic features: less than 10 mole fraction carbides and/or borides at 1300K; at least one carbide and one boride phase at 1300K; and eutectic carbides and/or borides at no less than 80K below the liquidus temperature of the ferritic or austenitic iron matrix phase.
 15. The method of claim 14, wherein a minimum carbon content in a liquid phase of the alloy layer is 0.5 wt. %.
 16. The method of claim 14, wherein the alloy layer comprises eutectic carbides and/or borides at no less than 80K below the liquidus temperature of a ferritic or austenitic iron matrix phase of the alloy layer in a fully diluted state.
 17. The method of claim 14, wherein the alloy layer has high abrasion resistance as characterized by a ASTM G65A mass loss of less than 0.5 grams.
 18. The method of claim 14, wherein the alloy layer comprises Fe and, in wt. %: B: about 0.1 to about 1.1; C: about 0.6 to about 2; Cr: about 0.5 to about 22; Mn: about 0 to about 1.15; Mo: about 0 to about 1; Nb: about 0 to about 8; Si: about 0 to about 0.65; Ti: about 0 to about 8; V: about 0 to about 10; W: about 0 to about 4; and Zr: about 0 to about
 8. 19. The method of claim 14, wherein the alloy layer comprises Fe and, in wt. %: B: 0.6-0.9; C: 0.75-1.25; Cr: 14.25-26; and Nb+Ti+V: 3.5-4.5.
 20. The method of claim 19, wherein the alloy layer further comprises, in wt. %: Mn: about 1.1; Mo: about 1; and Si: about 0.5. 